Gasket for prefabricated wall panel systems
A system includes a compressible, elongated gasket. The gasket includes first and second tubes aligned side-by-side and connected to each other along their common length by a first base and a second base, each of the first base and second base contacting both the first tube and the second tube. A method for sealing a joint between first and second wall panels is described. The method comprises obtaining a first compressible, elongated gasket; positioning the first gasket on an edge face of the first wall panel; attaching the first gasket to the edge face of the first wall panel; and placing the second wall panel adjacent to the first wall panel to compress the first gasket therebetween.
This application claims the benefit of priority from U.S. Provisional Patent Application No. 63/073,773, filed Sep. 2, 2020. This priority application is hereby incorporated in its entirety.
BACKGROUNDReferring to
The space between adjacent EIFS wall panels 10 should be sealed against air and moisture penetration at the joints 22 between panels 10. Conventionally, this is accomplished with caulking applied by workers from the exterior of the structure or building being constructed, often requiring the use of scaffolds and other support equipment. In the current state of the art, a backer rod is used to prevent sealants from penetrating too far into the joint, and sealant such as caulking material is applied at the joint. However, this method is labor intensive, cannot be applied during fabrication of the wall panel, and sometimes deteriorates over time, thereby requiring upkeep and replacement.
SUMMARYIn one aspect, a system comprises a compressible, elongated gasket. The gasket comprises first and second tubes aligned side-by-side and connected to each other along their common length by a first base and a second base, each of the first base and second base contacting both the first tube and the second tube.
In another aspect, a method for sealing a joint between first and second wall panels is described. The method comprises obtaining a first compressible, elongated gasket; positioning the first gasket on an edge face of the first wall panel; attaching the first gasket to the edge face of the first wall panel; and placing the second wall panel adjacent to the first wall panel to compress the first gasket therebetween.
This summary is provided to introduce concepts in simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the disclosed or claimed subject matter and is not intended to describe each disclosed embodiment or every implementation of the disclosed or claimed subject matter. Specifically, features disclosed herein with respect to one embodiment may be equally applicable to another. Further, this summary is not intended to be used as an aid in determining the scope of the claimed subject matter. Many other novel advantages, features, and relationships will become apparent as this description proceeds. The figures and the description that follow more particularly exemplify illustrative embodiments.
The disclosed subject matter will be further explained with reference to the attached figures, wherein like structure or system elements are referred to by like reference numerals throughout the several views. All descriptions are applicable to like and analogous structures throughout the several embodiments, unless otherwise specified.
While the above-identified figures set forth one or more embodiments of the disclosed subject matter, other embodiments are also contemplated, as noted in the disclosure. In all cases, this disclosure presents the disclosed subject matter by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that fall within the scope of the principles of this disclosure. While some of the drawings show exemplary dimensions of features in inches, other sizes are also suitable.
The figures may not be drawn to scale. In particular, some features may be enlarged relative to other features for clarity. Moreover, where terms such as above, below, over, under, top, bottom, side, right, left, vertical, horizontal, etc., are used, it is to be understood that they are used only for ease of understanding the description. It is contemplated that structures may be oriented otherwise.
DETAILED DESCRIPTIONAs shown in
In an exemplary embodiment of a prefabricated wall panel 10, gasket 24 is attached to one or more edges 13 of the wall panel 10, such as a left side edge, a top edge, and a right side edge, for example. Upon installation of the multiple wall panels to each other, the facing edge faces of adjacent wall panels will compress the gaskets 24 therebetween. This compression seals a space in the joint 22 between the adjacent wall panels, thereby reducing or eliminating infiltration of environmental elements such as wind, precipitation and dust, for example. Thus, use of the disclosed gaskets with prefabricated wall panel systems allows for effective sealing between adjacent panels from environmental elements without requiring conventional methods such as the subsequent application of caulk or other sealing materials that typically require workers to scale scaffolding for their implementation.
In an exemplary embodiment, gasket 24 is symmetrical so that the interior tube 28 and the exterior tube 30 are interchangeable, and either base 32 (or both bases 32) can have adhesive 26 (and optionally release liner 27) applied thereto. In other embodiments, the interior and exterior tubes could be different from each other; for example, the exterior tube 28 could have a larger diameter than the interior tube 30 to form a more robust seal against exterior elements. Having two tubes 28, 30 offers extra security and redundancy in case there is a leak or crack in one tube. Additionally, having bases 32 span the length of both tubes 28, 30 on both sides (top and bottom) of the tubes creates a wide and stable attachment surface on the exterior of gasket 24. The provision of cylindrical tubes 28, 30 within the gasket structure offers firm internal support for the exterior surface.
In exemplary embodiments, coupler 34 is formed so that adjacent and connected gaskets 24 are aligned generally linearly via coupler 34, and connectors 46, 48 and 50 are formed to define 90° connections between adjacent and connected gaskets 24. It is contemplated that coupler 34 and connectors 46, 48 and 50 may be formed to make gasket connections at angles other than 180° and 90°, such as other obtuse or acute angles between connected gaskets 24, depending on the design and configuration of the wall panels 10 and their assembly, as desired to make an effective seal therebetween.
In an exemplary embodiment, gasket 24 and each of connectors 34, 46, 48, 50 is formed of a resilient, compressible, durable, ultraviolet (UV) light resistant and weather resistant material. Suitable materials include, for example, EPDM (ethylene propylene diene monomer) rubber, a thermoplastic elastomer (TPE) mix of plastic and rubber, a thermoplastic olefin (TPO) polymer/filler blend, silicone, and combinations thereof. Connectors 34, 46, 48, 50 may be formed of a EPDM to be stiffer than gasket 24, for example. With the currently described system, the gaskets 24 and connectors 34, 46, 48, 50 can be applied to typically two to three edges of the wall panel 10 at the fabrication factory, so that no post-installation sealing is required after the system of wall panels is assembled together to clad the exterior surface of a building. A wall panel system installed using the disclosed gaskets is impervious to moisture and air penetration at joints 22 between the wall panels 10, and such protection is durable to withstand environmental elements over time. In another embodiment, gaskets 24 are applied to all edge faces 13 of a wall panel 10 at the fabrication point. Alternatively, gaskets 24 can be applied to one or more edge faces 13 of a wall panel 10 at the structure assembly site, before adjacent panels are mounted.
Non-limiting, exemplary embodiments of a system and method are described. In
In In an exemplary embodiment, a compressible, elongated gasket 24 comprises first and second tubes 28, 30 aligned side-by-side and connected to each other along their common length by a first base 32 and a second base 32, each of the first base 32 and second base 32 contacting both the first tube 28 and the second tube 30. In an exemplary embodiment, an adhesive 26 is disposed on at least one of the first base 32 and the second base 32.
In an exemplary embodiment, a system comprises a compressible coupler 34, 46, 48, configured to connect a plurality of said gaskets 24. In an exemplary embodiment, the coupler 34, 46, 48, 50 comprises a first set of first and second barrels 36, 38 configured to engage the first and second tubes 28, 30, respectively, of a first gasket 24 of the plurality of said gaskets 24. In an exemplary embodiment, the coupler 34, 46, 48, 50 comprises a second set of first and second barrels 36, 38 configured to engage the first and second tubes 28, 30, respectively, of a second gasket 24 of the plurality of said gaskets 24.
In an exemplary embodiment of coupler 34, 48, 50, the first set and the second set are aligned along a common linear orientation. In an exemplary embodiment of connector 46, 48, the first set and the second set have a mutually orthogonal orientation. In an exemplary embodiment, connector 48, 50 comprises a third set of first and second barrels 36, 38 configured to engage the first and second tubes 28, 30, respectively, of a third gasket 24 of the plurality of said gaskets 24. In an exemplary embodiment of connector 48, 50, the first set and the second set are aligned along a common linear orientation; and the first set and the third set have a mutually orthogonal orientation. In an exemplary embodiment, connector 50 comprises a fourth set of first and second barrels 36, 38 configured to engage the first and second tubes 28, 30, respectively, of a fourth gasket 24 of the plurality of said gaskets 24. In an exemplary embodiment of connector 50, the first set, second set, third set and fourth set have mutually orthogonal orientations.
In an exemplary embodiment, a first wall panel 10 comprises a first edge face 13, wherein a first said gasket 24 is attached to the first edge face 13. In an exemplary embodiment, a second wall panel 10 comprises a second edge face 13, wherein the first said gasket 24 is compressed between the first edge face 13 and the second edge face 13. In an exemplary embodiment, one of the first and second bases 32 of the first said gasket 24 is attached to the first edge face 13. In an exemplary embodiment, the first wall panel 10 comprises a second edge face 13, and wherein a second said gasket 24 is attached to the second edge face 13. In an exemplary embodiment, the first wall panel 10 comprises a third edge face 13, and a third said gasket 24 is attached to the third edge face 13.
In an exemplary embodiment, a method for sealing a joint 22 between first and second wall panels 10 is described. The method comprises obtaining a first compressible, elongated gasket 24; positioning the first gasket 24 on an edge face 13 of the first wall panel 10; attaching the first gasket 26 to the edge face 13 of the first wall panel 10; and placing the second wall panel 10 adjacent to the first wall panel 10 to compress the first gasket 24 therebetween. In an exemplary embodiment, the first wall panel 10 has an exterior side E and an interior side I, wherein positioning the first gasket 24 on the edge face 13 of the first wall panel 10 comprises aligning the first tube 28 proximate the exterior side E and aligning the second tube 30 proximate the interior side I. In an exemplary embodiment, attaching the first gasket 24 comprises adhering one of the first base 32 or second base 32 to the edge face 13 of the first wall panel 10. In an exemplary embodiment, the method comprises obtaining a second said compressible, elongated gasket 34 and a connector 36, 46, 48, 50, the method comprising attaching the connector 36, 46, 48, 50 between the first gasket 24 and the second gasket 24.
Although the subject of this disclosure has been described with reference to several embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the disclosure. For example, while the illustrated embodiments of tubes 28, 30 and barrels 36, 38 of connectors 34, 46, 48, 50 are depicted as cylindrical, it is contemplated that other mutually engageable shapes can also be used. In addition, any feature disclosed with respect to one embodiment may be incorporated in another embodiment, and vice-versa.
Claims
1. A system comprising:
- a compressible, elongated gasket comprising first and second tubes aligned side-by-side and connected to each other along their common length by a first base and a second base, each of the first base and second base contacting both the first tube and the second tube; and
- a compressible connector configured to connect a plurality of said gaskets.
2. The system of claim 1, comprising an adhesive disposed on at least one of the first base and the second base.
3. The system of claim 1, wherein the connector comprises a first set of first and second barrels configured to engage the first and second tubes, respectively, of a first gasket of the plurality of said gaskets.
4. The system of claim 3, wherein the connector comprises a second set of first and second barrels configured to engage the first and second tubes, respectively, of a second gasket of the plurality of said gaskets.
5. The system of claim 4 wherein the first set and the second set are aligned along a common linear orientation.
6. The system of claim 4 wherein the first set and the second set have a mutually orthogonal orientation.
7. The system of claim 4, wherein the connector comprises a third set of first and second barrels configured to engage the first and second tubes, respectively, of a third gasket of the plurality of said gaskets.
8. The system of claim 7 wherein:
- the first set and the second set are aligned along a common linear orientation; and
- the first set and the third set have a mutually orthogonal orientation.
9. The system of claim 7, wherein the connector comprises a fourth set of first and second barrels configured to engage the first and second tubes, respectively, of a fourth gasket of the plurality of said gaskets.
10. The system of claim 9 wherein the first set, second set, third set and fourth set have mutually orthogonal orientations.
11. The system of claim 1 comprising a first wall panel comprising a first edge face, wherein a first said gasket is attached to the first edge face.
12. The system of claim 11 comprising a second wall panel comprising a second edge face, wherein the first said gasket is compressed between the first edge face and the second edge face.
13. The system of claim 11 wherein one of the first and second bases of the first said gasket is attached to the first edge face.
14. The system of claim 11 wherein the first wall panel comprises a second edge face, and wherein a second said gasket is attached to the second edge face.
15. The system of claim 14 wherein the first wall panel comprises a third edge face, and wherein a third said gasket is attached to the third edge face.
16. A method for sealing a joint between first and second wall panels, the method comprising:
- obtaining a first compressible, elongated gasket comprising first and second tubes aligned side-by-side and connected to each other along their common length by a first base and a second base, each of the first base and second base contacting both the first tube and the second tube;
- positioning the first gasket on an edge face of the first wall panel;
- attaching the first gasket to the edge face of the first wall panel;
- obtaining a second said compressible, elongated gasket and a connector, the method comprising attaching the connector between the first gasket and the second gasket; and
- placing the second wall panel adjacent to the first wall panel to compress the first gasket therebetween.
17. The method of claim 16 wherein the first wall panel has an exterior side and an interior side, wherein positioning the first gasket on the edge face of the first wall panel comprises aligning the first tube proximate the exterior side and aligning the second tube proximate the interior side.
18. The method of claim 16 wherein attaching the first gasket comprises adhering one of the first base or second base to the edge face of the first wall panel.
4552790 | November 12, 1985 | Francis |
4590725 | May 27, 1986 | Kaminaga |
4616460 | October 14, 1986 | Nicholas |
4782636 | November 8, 1988 | Stoakes |
4861043 | August 29, 1989 | Anderson |
4866896 | September 19, 1989 | Shreiner et al. |
4999960 | March 19, 1991 | Herwegh et al. |
5687524 | November 18, 1997 | Ting |
5709056 | January 20, 1998 | Matsuyama et al. |
5893244 | April 13, 1999 | Magoon |
7389617 | June 24, 2008 | Grunewald |
8033066 | October 11, 2011 | Griffiths |
8950131 | February 10, 2015 | Loyd |
9340969 | May 17, 2016 | Shaw |
20200256061 | August 13, 2020 | Strickland |
3305075 | August 1984 | DE |
2169130 | March 2010 | EP |
1067976 | May 1967 | GB |
Type: Grant
Filed: Aug 31, 2021
Date of Patent: Jan 30, 2024
Assignee: CDM Capital Asset Group, Inc. (Overland Park, KS)
Inventors: Brice Neiman (Overland Park, KS), Randy Schneewind (Excelsior, MN), Doug Stegemoller (Peoria, AZ)
Primary Examiner: Christine T Cajilig
Application Number: 17/462,685
International Classification: E04B 1/61 (20060101);